Egg container



E. S. DREUX EGG CONTAINER Oct. l0, 1939.

Filed March l INVENTOR EMILE S. DREUX ATTORNEYS Patented Oct. 10, 1939 PATENT OFFICE EGG CONTAINER Emile S. Dreux, Smithfield Township, Monroe County, Pa.

Application March 1,

6 Claims.

The invention relates in general to an egg shipping or mailing package, or crate, of a type designed for storing and shipping eggs.

'I'he primary object of the invention is to provide an extremely simplified and inexpensive form of egg shipping package which will provide for a greater insurance against breakage of the eggs carried thereby than has been possible with known similar structures and to provide a structure so cheap that it may be thrown away after it has been once used.

The invention particularly features a composite construction including an outer mailable container and an insert therefore preferably formed of cardboard, preferably corrugated and of paper pulp, hereinafter referred to generically as paper, and which component parts of the insert may be formed from at, preformed stock capable of being stacked before use and from which stacks the package parts may be quickly fabricated by simple manual operation.

Another object of the invention is to provide give-away cushioning devices for progressively resisting tendencies of the eggs to move from their present positions in the package and thus tend to minimize rupturing shocks on the egg shells. This aspect of the disclosure is attained by providing an inexpensive form of paper means for suspending one or more layers of eggs in such 30 Way that under normal handling conditions the eggs are supported in space in such way that they are capable of a restrained freedom to move with the part engaging the same and which part is capable, in the event of any tendency of the egg to move from its holding means under the force of any unusual shock, to release gradually its holding effect on the egg, as by providing a form of holding means which may be torn under such conditions. The invention further contemplates the providing of separate cushioning means disposed in the path of possible escape of the eggs to interpose an additional or supplemental resistance to the escape or tendency to escape of the egg from its holding means under such abnormal handling conditions and in this way prevent or at least cushion all the eggs in any such tendency to move individually or in mass towards the outlining casing.

Still another object of the invention is to provide an aerated form of egg package for enhancing the keeping qualities of the contained eggs.

Broadly, lthis aspect of the invention is provided by locating air apertures in both the outer container as Well as in parts of the insert particularly featured in this disclosure in such way as 1937, Serial No. 128,457

will enhance the possibility of fresh air passing through the completed package.

Various other objects and advantages of the invention will be in part obvious from an inspection of the accompanying drawing and in part will be more fully set forth in the following particular description of one form of an egg shipping package embodying the invention, and the invention also consists in certain new and novel features of construction and combination of parts hereinafter set forth and claimed.

In the drawing:

Fig. 1 is a view in perspective showing a preferred embodiment of the invention and with parts of the top of the casing broken away at opposite ends to show normally concealed parts of the insert; and

Fig. 2 is a vertical transverse sectional view taken on the line 2-2 of Fig. 1 looking in the.

direction indicated by the arrows.

The egg shipping package illustrated comprises primarily an outer pasteboard container l0 and a unitary insert II snugly fitting therein. The container I0 is of a six-sided rectangular box-like construction preferably formed of relatively heavy cardboard and designed with the insert therein to provide suflicient structural strength to resist the crushing action to which such devices are commonly subjected in use as whenV sent through the mail. The outer container is provided with air vents I2 of the least possible size and number so as not to structurally weaken the container and at the same time to provide the necessary air circulation to keep the contained eggs E cool. The insert l I forms in effect a lining for the container so that for the most part the package is outlined by a double wall thickness of material. 'I'he insert Il constitutes a complete unit, separate from the container and which can be built up with its contained eggs and slid into the container. The insert is formed solely of four collars, I3, I4, I5 and I6, and four mats, I'I, I8, I9 and 20. The collars are long, four-slide rectangles, open at top and bottom and preferably formed of relatively thin corrugated cardboard and each having a height slightly less than konehalf of the depth of the interior of the container, having the same length and slightly less than one-half of the internal width of the container.

The mats are for the most part more or less flat sheets pressed toy shape or moulded from soft paper stock and each formed of twotraylike halves 2| and 22. Each half has: an outlining flange 23 with the central longitudinal flange common to the two halves scored longitudinally.

to form a hinge connection 24 between the two halves. Each half of the mat is moulded to form two lines of hollow depressions or projections 25, each line containing in the instant case, six depressions as shown in Fig. l, so that the package illustrated is designed to ship two dozen eggs. These depressions are somewhat frusto-conical in outline and as they approximate the shape of the larger end or half an egg, they will be referred to sometimes hereinafter as semi-egg shaped. The depressions are opened at their smaller end, that is, the end remote from the plane defined by the outlining flanges 23, to provide in each case a constricted opening 26 of less cross sectional area than the eggs. These openings are each designed to permit the adjacent end of its associated egg to project therefrom when the egg is longer than the completed egg receptacle 21 hereinafter described. The opening 26 is outlined by a give-away edge 2B, in this case shown to be outlined by a circle of V-shaped serrations 29 suiciently flexible to conform more or less to the contour of the part of the egg which engages them. The two lines of depressions in each half, 2I and 22, are symmetrically disposed on opposite sides of the hinge line 24 so that when one of the two halves is folded over on to the other as in the case of the mats I8 and I9 forming the mid-height line of mats in Fig. 2, there is formed a pair of egg holders 33 and 3I, one for each half of the complete package. It will be noted from the showing of the three eggs to the left of Fig. 2 that the egg receptacles 2l formed by the opposing pairs of depressions in the mat are not exactly egg-shaped but are slightly wider than the contained eggs at their mid-section and the conical side of each receptacle converges towards opposite ends of the egg so as to apply gentle pressure to the upper and lower portion of the eggs in spaced relation to the extreme ends of the egg. The upper mat Il and lower mat 20 extend in unfolded, fiat position across respectively the top and bottom of the insert with their depressions 25 projecting downwardly from the top and upwardly from the bottom to form cushioning cups 32 in line with any vertical movement, either upwardly or downwardly, of each egg from its associated receptacle.

The collars are arranged in two tiers of two collars each disposed in parallel and superposed relation with the outlining flange of one egg holder 30 positioned between and supported by the two collars I4 and I3 and the other egg holder 3I similarly suspended between the other two collars I6 and I5. The collars and the receptacles are so proportioned that the eggs are, in effect, held suspended in a non-rigid position, that is the eggs are capable of slight movement particularly in a Vertical direction and are spaced from the cushions 32 provided by the inwardly directed projections from the upper and lower mats. Each collar is provided with a longitudinally extending partition 33 extending between the two rows of projections therein. Each partition is provided with bent end fianges 34 and 35 engaging against the smaller ends of the collars to form at this portion a three layer thickness of material at opposite ends of the package. It will be seen from this structure that the partitions form internal reinforcements for the collars and in turn the collars form an internal reinforcement for the outer container. The long outer walls 36 and 3l oi each collar and the partition 33 form upstanding parallel walls between the top and bottom sides of the outer casing and thus provide supports between which each row of eggs is suspended irrespective as to whether the package is in a normally righted or upside down position. The adjacent edges 38 and, 39 of the two egg holders 30 and 3| coact in their edge to edge relation to form spacing means as shown at the middle of Fig. 2 to maintain the tiers apart. Likewise the scored or mid-flange portion 24 of the upper and lower mats forms more or less flat connecting and spacing means 4U and 4I between the tiers at the top and bottom of the insert. It is also suggested that the mats be provided with air vents G2 to permit the passage through the insert of air admitted and discharged through the outer air vents I2.

In actual practice the mats are not so accurately formed as appears from the drawing but one depression rounds more or less into the next adjacent depression both longitudinally and transversely of the showing in Fig. 1 and this has the effect of avoiding sharp lines which might tend to provide lines of weakness inviting tearing of the mats. The very roughness of the sheet from which the mats are formed tends to give some slight exibility and at least a slight degree of elasticity to the moulded parts.

In operation and assuming that it is desired to package two dozen eggs for shipment, one of the mats 20 is laid on a support with its formed cup-like projections 32 extending upwardly to eventually form the lower layer of cushions. Two of the collars I4 and I6 are each opened from their normally at collapsed position, and a partition 33 is inserted in each collar and fitted therein to maintain the collar in its open rectangular position. The lower collars thus formed are 1ocated on top of the lower mat. Two more mats are taken from the stock of such mats and each temporarily folded along its score line to form the two egg holders 3!) and 3l. The eggs E are then inserted one by one into the lower depressions and when each holder is filled the upper half thereof is closed over the eggs and the holders are then located with their outer flange edges on the upper .edges of the lower collars as indicated at Fig. 2. Similarly the upper collars I3 and I5 are formed with their contained partitions 33 and located on top o-f the egg holders. That is, the lower edges of the upper collars and their partitions are located on top of the anges of the egg holders. Finally, another mat I1 is laid in unfolded position on top of the upper collars with a similar flange to edge engagement. In this way there is formed twenty-four sets of depressions of which four are shown in Fig. 2, each set comprising in vertical alignment an upper cup-like cushion projecting downwardly, an egg receptacle containing an egg and a lower cushion. 'Ihe insert thus formed is fitted snugly within the container and when properly labelled is ready for shipment.

While the device features the utilization of the least possible amount of material in its construction, particularly in the construction of the insert, the package will stand considerable rough handling. The multi-layer construction of the outlining walls tends to resist externally applied knocks. The individual egg receptacles are contained deep within the insert and are capable of at least some slight freedom of movement under the surging action of the eggs suspended therein so that the parts are capable of shifting slightly under the thrust of the eggs against the contacting parts of the egg holders. The construction somewhat confines the possible tendency to movement of the egg in a more or less vertical direction and which movement is gently resisted by the inherent tendency of the depressions engaging the top and bottom halves ofthe eggs to resist being distorted. Further, in the event that one or more eggs tend to distort their associated receptacles, the resulting strain is transmitted to the adjacent somewhat roughened portions of the mat and therefrom eventually transferred to the supporting walls provided-by the collars and their contained partitions.

Under normal operating conditions, the top and bottom cushioning devices 32 herein featured do not come into operation and only become operative in the event that any egg becomes subjected to such a violent shock as to cause it to leave, or tend to leave, its associated receptacle. In the illustration at the right of Fig. 2, it is assumed that the displaced egg has been violently shaken and has moved downwardly from its initial position as illustrated by the three eggs to the left of the showing. In the showing the underside of the right hand egg has not only bent the serrations 29 downwardly into a distorted position but has actually torn the edge of the opening 26 at one or more places. Even though the mats are made of soft paper pulp material they do interpose some resistance to any such tearing action and any such resistance adds to the cushioning effect imposed on the escaping egg. Ordinarily, of course, the egg will be stopped at this point, but should it continue to lower itself beyond the position illustrated, the upstanding frusta-conical shaped cushioning projection will tend to crumble into a cushioning seat massed on the bottom of the outer container. This would mean that as the egg tended to proceed further towards the bottom of the outlining casing, it would progressively meet greater and greater resistance to its movement until gently stopped by the crumpled mass of paper formed by the crushed member 32. The device therefore constitutes a progressive cushioning structure even though it is made of paper. The eggs, in effect, float in space under normal conditions and the extensive engagement of the receptacle in contact with the egg avoids localizing of any rupturing forces on the egg and even when the egg is under such inherent force as would tend to tear it away from its receptacle, it contacts over a gradually increasing area with the more determined resistance of the cushioning devices and this result is attained even though the eggs may vary in size.

The fact that the container is provided with air vents permits the free passage of air through the container thereby preventing sweating of the eggs in transit. The normal use of the device does not in any way damage the parts and they can be subsequently demounted and restored to their original flat form ready for subsequent reuse.

By means of the device disclosed there is provided a collapsible package the parts of which can be easily and quickly assembled and in which eggs can be packed quickly without necessity of individual wrapping or special handling.

While there have been shown, described and pointed out in the annexed claims, certain novel features of the invention, it will be understood that various omissions ,substitutions and changes in the form and details of the device illustrated and in its operation may be made by those skilled in the art without departing from the spirit of the invention.

I claim:

1. In a device of the class described, the combination with an outer container, of an all-paper insert therefore comprising an egg holder including moulded cup-shaped holding means for engaging the top and bottom of an egg, said means having sufficient structural strength to suspend an egg in substantially fixed position and to so retain it under normal handling conditions, said means having openings at top and bottom into which the adjacent ends of the eggs protrude and the material outlining said openings providing a weakened area at its top and bottoni capable of being ruptured in the part engaging the egg in the event of a forceful, abnormal movement of the holder in space and thus to release or tend to release the contained egg, and cushioning means including opposing pairs of moulded cuplike projections disposed between the holder and the outer container on opposite sides of the container and provided with openings outlined by a give-away edge and disposed in the path of the movement or tendency to move of the egg from its holding means in either vertical direction whereby the openings in the cup-like cushioning projections will each tend to receive the adjacent end of the egg and act to resist movement of the egg into the same.

2. In a device of the class described, the combination of outlining means, means for suspending a plurality of eggs in spaced apart relation to each other within the outlining means, said suspending means including a separate and slightly flexible receptacle for each egg and having a configuration substantially that of the midportion of an egg and a mat having moulded therein egg cushioning means provided with constricted openings for receiving an end of an egg, one of said constricted egg receiving openings being spaced from and located between ea'ch receptacle and the adjacent side of the outlining means and acting to resist movement of each egg in either axial direction out of its associated receptacle.

3. A package for shipping two sets of eggs com. prising an outer pasteboard container, an allpaper insert therefore formed of four identical collars of corrugated pasteboard, arranged in two tiers of two superposed collars each and four identical moulded mats, two of the mats being each folded back upon itself to form two egg holders one for ea'ch set, one of the egg holders held between the two collars of one tier and the other egg holder held between the two collars of the other tier, edge portions of said egg holders projecting towards each other from the two tiers to form spacing means therebetween and the other two mats extending in unfolded position across and between the tops and bottoms of the two tiers and tending to maintain the two tiers in their spaced apart position.

4. In a device of the class described, the combination of ve separate parts comprising in superposed order a bottom mat, a lower collar, an intermediate mat, an upper collar and a top mat, said mats each comprising a sheet of tearable material having cup-like elements projecting from its general plane and the collars ea'ch comprising four side walls forming a rectangular.` structure open at its top and bottom and said collars superposed one above the other with the intermediate mat held thereby, said intermediate mat having the concaved sides of its cup-like elements facing each other and forming an egg container and the cup-like elements of the upper and lower mats forming cushions to receive any of the eggs which may tear themselves from the egg container, and each collar provided with a partition extending between opposite sides and acting to provide an internal reinforcement, between which and the sides of the collar are disposed the cup-shaped elements of the associated mats.

5. In a device of the class described, the combination of ve separate parts comprising in superposed order a bottom mat, a lower collar, an intermediate mat, an upper collar and a top mat, said mats each comprising a sheet of tearable material having cup-like elements projecting from its general plane and the collars each comprising four side walls forming a rectangular structure open at its top and bottom and said collars superposed one above the other with the intermediate mat held thereby, said intermediate mat having the concaved sides of its cup-like elements facing each other and forming an egg container and the cup-like elements of the upper and lower mats forming cushions to receive any of the eggs which may tear themselves from the egg container.

6. In a device of the class described, the combination of two sets of collars arranged in parallel relation and spaced apart horizontally, means for suspending two layers of eggs, one in each set of collars, and a one-piece mat extending between, lapping each set and tending to maintain them in their separated, horizontally spaced apart position, said mat provided within the outlines of ea'ch of the collars with integral projections, one for each of the eggs in the suspending means, and each projection having an open end providing a distortable seat disposed to receive and cushion its associated egg should it tend to escape from its suspending means.

EMILE S. DREUX. 

